Toothbrush

ABSTRACT

A toothbrush head comprises a first surface, a second outer surface opposite the first surface and an opening defined therebetween; a plurality of first cleaning elements extending from the first surface; and a carrier including a restricted end and a second cleaning element opposite the restricted end, the carrier movably mounted within the opening and the second cleaning element movable relative to the first surface.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/389,448 filed Mar. 14, 2003 and U.S. application Ser. No. 10/830,693filed Apr. 23, 2004, both of which applications are incorporated hereinby reference.

FIELD OF THE INVENTION

The invention relates generally to the field of oral care, and inparticular to toothbrushes. More specifically, the invention relates toa toothbrush head having one or more pivoting tufts of bristles, thehead having two portions that can move independent of each other.

BACKGROUND OF THE INVENTION

A Japanese patent document having an application number of 3-312978discloses a toothbrush having a multiplicity of tufts of nylon bristles.In a first embodiment shown in FIGS. 1, 2 and 3 of the document, aplurality of cylindrical recessed sections in the head are setorthogonally to the longitudinal axial direction of a shank and areformed at equal intervals. Column-shaped rotary bodies 5 arerespectively contained in the recessed sections. On the peripheralsurfaces of the rotary bodies 5, along the axial direction, projectedstrip sections 5 a are formed, and they are set in a state that they arepositioned at the opening sections of the recessed sections. At theopening sections of the recessed sections, contact surfaces to bepositioned on both the sides are formed. At both the ends of the uppersurfaces of the projected strip sections 5 a, nylon bristles 6 arearranged to be vertically erected.

As shown in FIG. 3 of the document, the arrangement described aboveallows bristles 6 to rotate during use of the brush. A problem with thisbrush is that two tufts of bristles are secured to each strip section 5a and thus must rotate in unison. As a result, an individual tuft ofbristles cannot rotate independently of its “partner” tuft. Theindividual tuft may thus be prevented from achieving optimal penetrationbetween two teeth during brushing because the partner tuft might contactthe teeth in a different manner and interfere with rotation of theindividual tuft.

FIGS. 4, 5 and 6 of the document disclose a second embodiment in whicheach tuft of bristles is secured to the head by a ball and socket typearrangement. While this embodiment allows each tuft of bristles toswivel independent of the other tufts, it does have disadvantages. If atuft of bristles is tilted out towards the side of the head and thattuft is positioned near the interface between the side and top surfacesof the teeth, chances are increased that the bristle tips will not evenbe in contact with the teeth during brushing. Further, the randomorientation in which the tufts can end up after brushing detracts fromthe attractiveness of the brush.

The Japanese reference also discloses that the brush head is made of aunitary structure. As such, water cannot flow through any centralportion of the brush head, thereby inhibiting the cleanability of thebrush. Further, the unitary head structure does not allow differentportions of the head to move independently of each other. Accordingly,the bristle tufts extending from the tuft cannot accommodate the varyingtooth surfaces as well as a brush in which the head has two or moreportions that can move or flex independent of each other.

SUMMARY OF THE INVENTION

The present invention is directed to overcoming one or more of theproblems set forth above. Briefly summarized, according to one aspect ofthe present invention, a toothbrush head has a tooth cleaning elementextending from the head. The head is divided into at least two portionswhich can be moved independent of each other. The tooth cleaning elementis rotatable relative to that portion of the head from which it extends.

According to another aspect of the invention, a tooth cleaning elementincludes one or more tooth cleaners, a base support, and an anchorpivot. One end of the one or more tooth cleaners is secured to a firstend of the base support. One end of the anchor pivot is secured to asecond end of the base support. The anchor portion has a larger sectionfurther from the base support than a smaller section of the anchorportion.

In accordance with a third aspect of the invention, a method of making atoothbrush head includes molding a plastic toothbrush head in a mold.The head has two distinct portions which are spaced a predetermineddistance from each other. The head is removed from the mold. At leastthat part of the head where the two head portions connect is heated. Thetwo head portions are moved towards each other. At least that part ofthe head where the two head portions connect is cooled such that the twohead portions will now remain in positions where they will be spacedapart a distance which is less than the predetermined distance.

According to a fourth aspect of the invention, a method of making atoothbrush head includes molding a plastic toothbrush head in a mold.The head has at least one hole therein which extends all the way throughthe head. The head is removed from the mold. A tooth cleaning element isinserted into the hole

These and other aspects, objects, features and advantages of the presentinvention will be more clearly understood and appreciated from a reviewof the following detailed description of the preferred embodiments andappended claims, and by reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the toothbrush head of FIG. 1;

FIG. 2 is a top view of the head of FIG. 1;

FIG. 3 is a side view of the head of FIG. 1;

FIG. 4 is a bottom view of the head of FIG. 1;

FIG. 5 is a side view of the head of FIG. 1 showing one of the headportions flexing;

FIG. 6 is a top view of the head of FIG. 1 with the two head portionsseparated from each other;

FIG. 7 is a top view of the head of FIG. 1 after the head portions havebeen positioned closer to each other;

FIG. 8 is a front view of a pivoting tuft taken along the lines 8-8 ofFIG. 13;

FIG. 9 is a side view of the pivoting tuft of FIG. 8 taken along lines9-9;

FIG. 10 is a top view of one of the holes in the head for receiving thepivoting tuft (see FIG. 6);

FIG. 11 is a sectional view of FIG. 10 taken along lines 11-11;

FIG. 12 is a sectional view of FIG. 10 taken along lines 12-12;

FIG. 13 is a side view of the head of FIG. 1 (a portion is removed tofacilitate viewing) and a pivoting tuft prior to insertion into thehead;

FIG. 14 is a side view of the head of FIG. 1 (a portion is removed tofacilitate viewing) and a pivoting tuft after insertion into the head;

FIG. 15 is a side view of the pivoting tuft showing its motion;

FIGS. 16A-C are sectional views of FIG. 15 taken along the lines16A-C-16A-C;

FIG. 17 is a perspective view of a tooth cleaner in the form of a ribbedfin; and

FIG. 18 is a side view of the ribbed fin of FIG. 17.

DETAILED DESCRIPTION

Beginning with FIGS. 1-5, there is shown a toothbrush head 16 whichextends from a neck 14 which extends from a handle (not shown) to form atoothbrush. The type of handle is not germane to the present invention.The head and handle are preferably made of polypropylene. The head has aserpentine split 18 which divides the head into two portions 20 and 22.An end of the split 13 near neck 14 is preferably circular in shape (seeFIG. 2). As shown in FIG. 5, the split in the head allows portions 20and 22 to flex or move independent of each other during use of thetoothbrush, thus facilitating cleaning of the teeth.

Split 18 can also be defined as an opening in the head between headportions 20 and 22. This opening allows water to flow through the head,thereby enhancing cleaning of the top head surface which typically getscaked with toothpaste in spite of efforts to rinse the head clean.

Head portion 20 includes a projecting part 24 which fits (at leastpartially) into a recess 26 (see FIG. 6) defined by portion 22.Projecting part 24 has several tufts of bristles extending from it (tobe described in further detail below) and is surrounded on three sidesby head portion 22.

Referring now to FIGS. 2 and 3, each of the tufts of bristles on head 16will be described. A first pair of tufts 28 are located towards the freeend of the head, one on each head portion 20, 22. Each tuft has bristles(tooth cleaners) which preferably are each made ofpolybutylene-terepthalate (PBT) and have a diameter of 0.007 inches. Theshortest bristles in tuft 28 have a length of 0.420 inches with theremaining bristles increasing in length steadily to a tip of the tuft.Each tuft tilts away from the handle by an angle of preferably about 12degrees relative to that portion of the surface of the head from whichit projects. As shown in FIG. 2, tufts 28 have a larger cross-sectionthan any other tuft on the head.

A second group of tufts are pivoting tufts 30 (the only tufts on thehead which are rotatable). There are four tufts 30 on each head portion20, 22 which are located towards the outside of the head. Each tuft 30can pivot up to about 15 degrees to either side of a vertical positionon the head, more preferably being able to pivot up to about 8 degreesto either side of a vertical position on the head. The pivoting of tufts30 is roughly towards or away from neck 14. Each tuft 30 includes a basesupport 32 made of polypropylene. The bristles are made of polyamid6.12, have a diameter of 0.008 inches and extend 0.420 inches above thebase support.

A third group of tufts 34 extend perpendicular to the head. There arefour tufts 34 on each head portion 20, 22 which alternate with tufts 30.When viewed from the top (FIG. 2) the tufts are oval in shape (similarto tufts 30 but larger). In other words, the tufts 34 and 30 have ovalshaped cross-sections. Each tuft 34 has bristles which are made ofpolyamid 6.12, have a diameter of 0.006 inches and extend above the headby about 0.385 inches.

A fourth group of tufts 36 are located towards the inside of the head.There are two such tufts on each head portion 20, 22. Each tuft 36extends perpendicular to the head. The bristles of tuft 36 have adiameter of 0.006 inches, are made of polyamid 6.12 and rise about 0.360inches above the head.

A fifth and final group of tufts 38 are also located towards the insideof the head (away from a perimeter 21 of the head). There are 4 pairs oftufts 38. In each pair one tuft is closer to neck 14 than the othertuft. In each pair of tufts 38, (a) a base of one tuft is closer to afirst side of the head and this one tuft leans towards a second side ofthe head, and (b) a base of the other tuft is closer to the second sideof the head and this other tuft leans towards the first side of thehead. As such, the tufts in each pair lean across each other. The angleof tilt towards the side of the head is about five degrees. Each tuft 38bristles which are made of PBT, have a bristle diameter of about 0.007inches and extend about 0.460 inches above head 16. Each tuft 38 has anoval cross-section with a long dimension of the oval being oriented inthe direction of tilt.

The bristles used on the head can be crimped (see U.S. Pat. No.6,058,541) or notched (see U.S. Pat. No. 6,018,840). Other types oftooth cleaners besides bristles can be used. For example, a tuft ofbristles could be replaced by an elastomeric fin. The US patents listedin this paragraph are incorporated herein by reference.

Turning now to FIG. 6, a description will now be provided as to how thetoothbrush (head) is made. In a first step, the head, neck and handle ofthe toothbrush are injection molded in a mold. During this injectionmolding step, tufts 28, 34, 36 and 38 are secured in the head by ahot-tufting process. Hot-tufting processes are notoriously well known bythose skilled in the art (see e.g. U.S. Pat. Nos. 4,635,313; and6,361,120; British patent application 2,330,791; and European patentapplication 676,268 A1).

Briefly, hot-tufting involves presenting ends of a multiplicity ofgroups of plastic filaments into a mold. Each group of filament endsinside the mold is optionally melted into a blob. Each filament group iscut to a desired length (either before or after being introduced intothe mold) to form a tuft of bristles. The mold is closed and moltenplastic is injected into the mold. When the plastic solidifies, it locksone end of the tufts of bristles into the head of the toothbrush.

It can be seen in FIG. 6 that the opening 18 between head portions 20and 22 is much wider at this point than in the heads final form (seeFIG. 2). In other words, head portions 20 and 22 are spaced apredetermined distance (preferably at least about 1 mm) from each other.Further, through holes 40 are created during the molding step forreceiving pivoting tufts 30 at a later point in the manufacturingprocess. Holes 40 will be described in greater detail below.

With reference to FIG. 7, after the toothbrush is removed from the mold,heat 42 is applied to the head near the neck and to part of the neck(hereinafter the neck). The heat can be applied in a number of waysincluding hot air, radiant heating, ultrasonic or convection (e.g. hotoil) heating. Here the heat is shown being applied to the sides of theneck. It is preferable to apply the heat to the top and bottom surfaceof the neck. The heat brings the plastic up to 1.0-1.12 times its glasstransition temperature (when temperatures are measured in the Kelvinscale). The plastic should not be heated above 1.12 times its glasstransition temperature in order to avoid damaging the plastic. Morepreferably, the plastic is heated to about 1.03-1.06 times its glasstransition temperature (measured in degrees Kelvin). The glasstransition temperature for polypropylene is about 100 degrees centigradewhereas the glass transition temperature for copolyester andpolyurethane is about 65 degrees centigrade.

Pressure 44 is then applied to head portions 20, 22 to move the portionstowards each other. Once head portions 20, 22 are in the position shownin FIG. 2, the heated portion of the head/neck is cooled by, forexample, exposing the heated portion to a cold gas or liquid. If roomtemperature air is used to cool the neck, such air should be applied forabout 20-25 seconds. This has the effect of forming the two headportions into their final positions.

In order to achieve short process times, the highest temperature heatsource which will not damage the plastic should be used. If too hot aheat source is used and/or if the heat is applied for too long, theplastic can be damaged. If the heat source is not hot enough, theprocess will take too long and/or head portions 20, 22 will not remainin their final desired positions. If the head/neck are made ofpolypropylene and hot air is used to heat the neck, (a) the heated airshould be at a temperature of about 170 degrees centigrade and should beapplied to the neck for about 70 seconds, (b) the polypropylene shouldbe raised to a temperature of about 140 degrees centigrade, and (c) anozzle which applies the hot air to the neck should be about 10 mm fromthe neck.

If copolyester or polyurethane is used as the material for the headneck, (a) the heated air should be at a temperature of 250 degreescentigrade and should be applied to the neck for about 10 seconds, (b)the material should be raised to a temperature of preferably 95-100degrees centigrade, and (c) a nozzle which applies the hot air to theneck should be about 15-20 mm from the neck.

Heating the respective materials above for the time indicated allows thematerial to be softened and mechanically bent into its final form.Exceeding the heating times above could cause the material to overheatand become damaged.

Turning to FIGS. 8 and 9, each pivoting tuft 30 has a multiplicity ofbristles 46, a base support 48 and an anchor pivot 50. The bristles aresecured to and extend from a first end 52 of the base support while afirst end 54 of the anchor pivot extends from a second end 56 of thebase support. The base support and anchor pivot are preferably a unitarystructure made of the same material. Anchor pivot 50 includes a firstportion 58 near the first end 54 and a second portion 60 near a secondend 62 of the anchor pivot. First portion 58 is smaller in an X an Ydimension than second portion 60. Base support 48 is larger in an X andY dimension than second portion 60 of the anchor support. Second portion60 includes a pair of lips 63. The anchor pivot defines an opening 64therethrough.

Tuft 30 can also be made by a hot-tufting type process as describedabove. Instead of injecting plastic into the mold to form a toothbrushhandle, neck and head, the plastic is injected into a mold to form basesupport 48 and anchor pivot 50, capturing bristles 46 when the injectedplastic cools.

With reference to FIGS. 10-12, through holes 40 (FIG. 6) will now bedescribed. Each hole 40 extends from a top surface 66 of the brush headthrough a bottom surface 68. Hole 40 includes first and second portions70 and 72. Portion 72 is substantially a parallelepiped except that someof its lower section is rounded off (see FIG. 11). Portion 70 is alsosubstantially a parallelepiped except that two of its sides are flaredto the sides by about 15 degrees (see FIG. 12). Hole portion 72 islonger in a dimension A than hole portion 70 (FIG. 11). Hole portion 70has about the same width in a dimension B as hole portion 72 where holeportions 70 and 72 meet (FIG. 12). Dimensions A and B are substantiallyperpendicular to each other in this embodiment. A pair of lips 73 aredefined by this arrangement.

Turning now to FIGS. 13-16, the insertion of pivoting tufts 30 intoholes 40 will be described. A tuft 30 is positioned over a hole 40 withend 62 of anchor pivot 50 facing the hole (FIG. 13). As shown in FIGS.16A-C, tuft 30 is moved towards hole 40 until end 62 starts to enter thehole (FIG. 16A). Tuft 30 is then pressed into the hole causing sides ofhole portion 70 to squeeze second portion 60 of the anchor pivot.Accordingly, anchor pivot 50 collapses causing opening 64 to becometemporarily smaller. Tuft 30 is then pushed all the way into hole 40(FIG. 16C) at which point the resilient plastic anchor pivot springsback to its form shown in FIG. 16A. This paragraph describes a snap-fitretention of tuft 30 to the head.

Referring to FIG. 16C, base support 48 is longer in the A dimension thanhole portion 70 and thus prevents tuft 30 from being pressed furtherinto hole 40. Second portion 60 is also longer in the A dimension thanhole portion 70 and so prevents tuft 30 from moving back out of hole 40.This is due to the fact that lips 63 (FIG. 8) engage lips 73 (FIG. 11).This arrangement also prevents tuft 30 from rotating about the long axisof the bristles.

As shown in FIG. 15, tuft 30 pivots when it is engaged by, for example,portions of the oral cavity during brushing. Preferably each tuft 30 canpivot up to about 15 degrees to either side of a position perpendicularto surface 66.

Turning to FIGS. 17 and 18, another type of tooth cleaning element inthe form of a fin 80 is disclosed. Each fin is supported by a basesupport 48 and an anchor pivot 50 (both not shown) as described above,allowing the fin to pivot on the brush head. Alternatively, a fin can besecurely affixed to the head so that it does not pivot. The fin iscreated of a thermoplastic elastomer (TPE) by an injection moldingprocess. In this embodiment, a textured surface is provided by a seriesof ribs 82. These ribs enhance cleaning of the oral cavity. The ribs areformed by injection molding a TPE over the fin. The ribs are preferablysofter than the fin. Alternative textured surfaces (e.g. dimples) can beused in place of the ribs.

As shown in FIG. 18, the fin has a width of preferably about 0.030inches. The long dimension of the fin above the base support ispreferably 0.420 inches. A tip 84 of fin 80 has a width of preferably0.007 inches. The distance from the base of the ribs to tip 84 is about0.168 inches whereas the distance from the top of the ribs to the tip isabout 0.079 inches. The top of the ribs have a width of about 0.035inches. The ribs (textured surface) preferably extend about 2-12 milaway from said fin.

According to another aspect of the invention, the toothbrush comprisesan electric toothbrush.

Suitable electric toothbrushes may include a vibrating, oscillating orrotating brush head, or any other conventional electric brushhead. Theelectric toothbrush includes an electric motor.

The invention has been described with reference to a preferredembodiment. However, it will be appreciated that variations andmodifications can be effected by a person of ordinary skill in the artwithout departing from the scope of the invention.

1. A toothbrush head comprising: a first surface, a second outer surfaceopposite the first surface and an opening defined therebetween; aplurality of first cleaning elements extending from the first surface;and a carrier including a restricted end and a second cleaning elementopposite the restricted end, the carrier movably mounted within theopening, the second cleaning element movable relative to the firstsurface; wherein the opening comprises a constriction that representsthe smallest cross-section of the opening and that retains the carrierin the opening or prevents the carrier from passing through the secondsurface; wherein the restricted end of the carrier is positioned betweensaid constriction and a plane defined along said second outer surface;and wherein the carrier enables movement of the second cleaning elementfrom a first position perpendicular to the first surface, to a secondposition angled relative to the first surface.
 2. The toothbrush head ofclaim 1, wherein the carrier includes a rounded profile along at leastone side thereof.
 3. The toothbrush head of claim 1, wherein the carrieris a ball joint.
 4. The toothbrush head of claim 1, wherein the secondcleaning element is elastomeric.
 5. The toothbrush head of claim 1,wherein the second cleaning element includes a massaging element.
 6. Thetoothbrush head of claim 1, wherein the carrier extends beyond a planedefined by the first surface such that the second cleaning elementextends from a position that is spaced from the first surface.
 7. Thetoothbrush head of claim 1, the carrier further comprising a platformwhich extends the second cleaning element.
 8. The toothbrush head ofclaim 7, wherein the platform is wider than the second cleaning elementat a junction of the second cleaning element and the platform.
 9. Anelectric toothbrush comprising: an electric motor; and a first surface,a second outer surface opposite the first surface and an opening definedtherebetween; a plurality of first cleaning elements extending from thefirst surface; and a carrier including a restricted end and a secondcleaning element opposite the restricted end, the carrier movablymounted within the opening, the second cleaning element movable relativeto the first surface; wherein the opening comprises a constriction thatrepresents the smallest cross-section of the opening and that retainsthe carrier in the opening or prevents the carrier from passing throughthe second surface; wherein the restricted end of the carrier ispositioned between said constriction and a plane defined along saidsecond outer surface; and wherein the carrier enables movement of thesecond cleaning element from a first position perpendicular to the firstsurface, to a second position angled relative to the first surface. 10.The electric toothbrush of claim 9, wherein the carrier includes arounded profile along at least one side thereof.
 11. The electrictoothbrush of claim 9, wherein the carrier is a ball joint.
 12. Theelectric toothbrush of claim 9, wherein the second cleaning element iselastomeric.
 13. The electric toothbrush of claim 9, wherein the secondcleaning element includes a massaging element.
 14. The electrictoothbrush of claim 9, wherein the carrier extends beyond a planedefined by the first surface such that the second cleaning elementextends from a position that is spaced from the first surface.
 15. Theelectric toothbrush of claim 9, the carrier further comprising aplatform from which extends the second cleaning element.
 16. Theelectric toothbrush of claim 9, further comprising a cleaning elementdriven by the electric motor.
 17. The electric toothbrush of claim 16,wherein the driven cleaning element rotates.
 18. The electric toothbrushof claim 17, wherein the driven cleaning element oscillates.